GD50 Ops Man 5-05 Ver 4.indb
Contents
1. LON lt 2 L He gt gt c 2 a shown smaller than actual size HOSE PRESSURE RATING The rated working pressure of the hydraulic hose must be equal to or higher than the relief valve setting on the hydraulic system HTMA REQUIREMENTS HYDRAULIC SYSTEM REQUIREMENTS FLOW RATE TOOL OPERATING PRESSURE at the power supply outlet SYSTEM RELIEF VALVE SETTING at the power supply outlet MAXIMUM BACK PRESSURE at tool end of the return hose Measured at a max fluid viscosity of at min operating temperature TEMPERATURE Sufficient heat rejection capacity TYPE 1 4 6 gpm 15 23 lpm 2000 psi 138 bar 2100 2250 psi 145 155 bar 250 psi 17 bar 400 ssu TOOL CATEGORY TYPE Il 11 13 gpm 26 34 lpm 42 49 lpm 2000 psi 2000 psi 138 bar 138 bar 2100 2250 psi 2100 2250 psi 145 155 bar 145 155 bar 250 psi 250 psi 17 bar 17 bar 400 ssu 400 ssu TYPE Ill TYPE RR 9 10 5 gpm 34 40 1 2000 psi 138 bar 2200 2300 psi 152 159 bar 250 psi 17 bar 400 ssu 82 centistokes 82 centistokes 82 centistokes 82 centistokes 140 F 60 C 140 F 60 C to limit max fluid temperature to at max expected ambient temperature Min cooling capacity 3 hp o hp 7 hp 6 hp at a temperature difference of 2 24 kW 3 73 kW 4 47 kW 5 22 kW between ambient and fluid temps 40 F 402. 3 Advance the valve stem by turning the gauge end clock wise 2 Read the pressure on the gauge It should be between 500 700 psi 35 48 bar 4 Connect the charging assembly to the valve on the tester 3 If the pressure is low recharge the tool 5 Adjust the regulator on the nitrogen bottle to 600 psi 42 bar Liquid Filled Gauge w Snub Valve Charge Fitting Nitrogen Tank Not included in Kit Charging Valve 31254 ACCUMULAT R CHARGE Includes Liquid Filleq Gauge w Snub Valve Hose Charge Fitting 02835 Tester Box not pictured Gauge s 02835 TESTER Chuck 11 EQUIPMENT PROTECTION 8 CARE NOTICE In addition to the Safety Precautions in this manual observe the following for equipment protection and care Make sure all couplers are wiped clean before connection The hydraulic circuit control valve must be in the OFF position when coupling or uncoupling hydraulic tools Failure to do so may result in damage to the quick couples and cause overheating of the hydraulic system Always store the tool in a clean dry space safe from damage or pilferage Make sure the circuit PRESSURE hose with male quick disconnect is connected to the IN port The circuit RETURN hose with female quick disconnect is connected to the opposite port Do not reverse circuit flow This can cause damage to internal seals Always replace hoses couplings and other parts with replacement parts r
3. F 40 F 40 F 22 22 22 22 Do not operate the tool at oil temperatures above 140 60 Operation at higher temperatures can cause operator discomfort at the tool FILTER 25 microns 25 microns 25 microns 25 microns Min full flow filtration 30 gpm 30 gpm 30 gpm 30 gpm Sized for flow of at least 114 lpm 114 lpm 114 lpm 114 lpm For cold temp startup and max dirt holding capacity HYDRAULIC FLUID Petroleum based premium grade anti wear non conductive VISCOSITY at min and max operating temps 100 400 ssu 100 400 ssu 100 400 ssu 100 400 ssu 20 82 centistokes NOTE When choosing hydraulic fluid the expected oil temperature extremes that will be experienced in service determine the most suitable temperature viscosity characteristics Hydraulic fluids with a viscosity index over 140 will meet the require ments over a wide range of operating temperatures SSU Saybolt Seconds Universal NOTE These are general hydraulic system requirements See tool Specification page for tool specific requirements OPERATION PREOPERATION PROCEDURES PREPARATION FOR INITIAL USE Each unit as shipped has no special unpacking or assem bly requirements prior to usage Inspection to assure the unit was not damaged in shipping and does not contain packing debris is all that is required Check Hydraulic Power Source 1 Using a calibrated flowmeter and pressure gauge c
4. GD50 HYDRAULIC ROD DRIVER SERIOUS INJURY OR DEATH COULD RESULT FROM IM PROPER REPAIR OR SERVICE OF THIS TOOL REPAIRS AND OR SERVICE TO THIS TOOL MUST ONLY BE DONE BY AN AUTHORIZED AND CERTIFIED DEALER To avoid serious injury or death SAFETY OPERATION AND MAINTENANCE USER S MANUAL Stanley Hydraulic Tools 3810 SE Naef Road Milwaukie OR 97267 5698 Stanley Hydraulic Tools 2005 _ OPS MAINT USA CE 203 659 5660 Printed in U S A FAX 503 652 1780 39234 5 2005 ver 4 www stanley hydraulic tools com TABLE OF CONTENTS SAFET YMD OE al ln a 4 SAFETY PRECAUTIONS RNA 5 TOOL STICKERS amp TAGS RMMMMMMMMMMMEK N i gae MM 6 HYDRAULIC HOSE REQUIREMENTS ttt rtt rtt ALEEA EEE n nnns 7 HOSE TYPES cccccccsecsccsecseceesucsucsesuesucsucsecscsucsucescrscuesucsucsesarsucsussussesassucsucsesaesucsucsusstsucsucsssesuesassucsucsucsseesatsucseceesessacscsesecsaescseceeee 7 HOSE SAFETY TAGS JR 7 HTMA REQUIREMENTS cccccsecsecsesecsessessssucsucsucsesutsucsusensussucsussscsesecsucsussssersuesussssuesacsucsusessuesussssetsassacssssnsetsssetsasssstseeseeeseeseeeeen 8 9 PREOPERATION PROCEDURES ccsessscssssssessessessesucsessessesucsucsussesucsucsussesaesucsecseseesucsucsucersassussussesucsacsusssaesucsussessesaessesatsacsessesecen 9 PREPARATION FOR INITIAL USE tette 9 dioe NR 9 CHECK TRIGGER MECHANISM terere ttt ttt ttt rtt ttt 9 ONNO n
5. Costs incurred to remove a Stanley manufactured component in order to service an item manufactured by other manufacturers ALTERATIONS amp MODIFICATIONS Alterations or modifications to any tool or part All obligations under this warranty shall be terminated if the new tool or part is altered or modified in any way NORMAL WEAR any failure or performance deficiency attributable to normal wear and tear such as tool bushings retaining pins wear plates bumpers retaining rings and plugs rubber bushings recoil springs etc INCIDENTAL CONSEQUENTIAL DAMAGES To the fullest extent permitted by applicable law in no event will STANLEY be liable for any incidental consequential or special damages and or expenses FREIGHT DAMAGE Damage caused by improper storage or freight handling LOSS TIME Loss of operating time to the user while the tool s is out of service IMPROPER OPERATION Any failure or performance deficiency attributable to a failure to follow the guidelines and or procedures as outlined in the tool s operation and maintenance manual MAINTENANCE Any failure or performance deficiency attributable to not maintaining the tool s in good operating condition as outlined in the Operation and Maintenance Manual HYDRAULIC PRESSURE amp FLOW HEAT TYPE OF FLUID Any failure or performance deficiency attributable to excess hydraulic pressure excess hydraulic back pres sure excess hydraulic flow excessive heat or incorrect hydraul
6. Included with item 14 38629 Valve Body Assy 10536 Selector Screw 00026 O ring 04381 Back up Ring Bumper Used on Serial No 430 amp 65813 Als 04379 O ring 04378 Porting Block 371071 Washer 35784 Hose Assy Model GD50132RF 1 2 and 5 8 inch rods Bee Model GD50133RF 3 4 and 1 inch rods 16070 Retaining Ring Dau Verify the correct model number before ordering 13568 Back up Ring Seal Kit GD50 Rapid Fire Model 04595 ant ibi All Other Models 13552 38631 Valve Spool 00936 Adaptor 24059 Male Coupler Body 24058 Female Coupler Body 04382 Automatic Valve 04571 Push Pin 02900 Roll Pin 37425 04383 Flow Sleeve Tube 04384 Flow Sleeve 04605 Push Pin 16 WARRANTY Stanley Hydraulic Tools hereinafter called Stanley subject to the exceptions contained below warrants new hydraulic tools for a period of one year from the date of sale to the first retail purchaser or for a period of 2 years from the shipping date from Stanley whichever period expires first to be free of defects in material and or workmanship at the time of delivery and will at its option repair or replace any tool or part of a tool or new part which is found upon examination by a Stanley authorized service outlet or by Stanley s factory in Milwaukie Oregon to be DEFECTIVE IN MATERIAL AND OR WORKMANGHIP EXCEPTIONS FROM WARRANTY NEW PARTS New parts which are obtained individually ar
7. LS DESCRIPTION PART NUMBER USAGE O ring Tool Kit 04337 General Service of Seals Split Rings 04908 Used with 04910 Flow Sleeve Removal Tool 04919 Flow Sleeve Removal Flow Sleeve Removal Tube 04910 Used with 04908 amp 05508 Bearing Puller Kit 05064 General Bearing Pulling Accumulator Disassembly Tool 05508 Used with 04910 Tamper Sleeve Tool 01120 Used to Pull Porting Block from Valve Block Accumulator Cylinder Puller 05640 An Aluminum Disk handy for protecting parts when using an arbor press Serial Number 430 and Above C Neu DDD PARTS ILLUSTRATION 15 mpm mpm 35770 Handle Bar 04954 Piston 10351 Capscrew 02022 O ring 07493 O Ring Plug Male 04387 Wiper Ring 05243 Orifice Plug Included with Item 13 04780 Back up Washer 20499 Charge Valve 04386 Cup Seal 04374 Lock Nut 12139 Side Rod 15190 Top Plate 43527 Adaptor Block 00720 Set Screw 12143 Upper Anvil Stop 07479 Diapragm 12146 Spring 00293 O ring Rod Anvil 5 8 inch rods 36106 Model GD50132 15188 Valve Spool Rod Anvil 3 4 to 1 in Rods Model GD50133 35752 Anvil Guide Serial No 429 amp Below 65812 Anvil Guide Serial No 430 amp Above 04058 Spring 35751 11588 Accumulator Valve Block 01605 O ring Included with Item 15 35753 Guide Housing 350000 Elbow 45
8. RAM 9 OPERATING PROCEDURES ttt ttt rtt EEE EEE rtt rtt 9 INLINE CONTROL VALVEOPERATION c scsscssessssussessesecsucsucsessccucsucsscecsucsuceesssssssassuesuseesussucsessesecsuesteetsstsasssstsstsststsseetseteetesesee 9 SETTING FOR OPEN CENTER O C OR CLOSED CENTER 9 gf EVA ane ia gg a ni 10 OPERATING THE VALVE cccccccsessessesscsscsecsussesucsucsucsussesucsucsscsssussuesucssssesussucsucsesacsussucsssansassussucseseesussasatsetsacsresecsatstsetsetsneesestseeees 10 COLD WEATHER OPERATION scsscssesscsessussessesecsucsucsesucsucsscsscessucsucsusesussucsucsusassussucesseesassussucsessesutsasssstsetsusssetsressussesitsasatsaeees 10 CHARGING THE trt ttt 11 TESTING THE ACCUMULATOR PRESSURE 11 EQUIPMENT PROTECTION amp CARE teret ttt 12 isis efe C 13 SPECIFICATIONS ARNA 14 gt eie e MU I Mi 14 PARTS ILLUSTRATION tette ttt EEA LELAS LE EAA L LEAI ttes Ds DD 15 PARTS B zy ERR RR sn ina annann ai nn una nan asna stiga nanna pa aaa nanna 16 TN STS NNA R 17 SERVICING THE STANLEY HYDRAULIC Rod Driver This manual contains safety operation and routine maintenance instructions Stanley Hydraulic Tools recommends that servicing of h
9. UPLINGS IF ANY OF THESE CONDITIONS EXIST REPLACE THE HOSE IMMEDIATELY DEPARTMENT INSTRUCTIONS NEVER USE TAPE OR ANY DEVICE TO ATTEMPT TO MEND THE HOSE 6 AFTER EACH USE STORE IN A CLEAN DRY AREA DO NOT REMOVE THIS TAG OVL SIHL LON shown smaller than actual size THE TAG SHOWN BELOW IS ATTACHED TO CONDUCTIVE HOSE DANGER DANGER DO NOT USE THIS HYDRAULIC HOSE ON OR NEAR ELECTRIC LINES THIS HOSE IS NOT LABELED OR CERTIFIED AS NON CONDUCTIVE USING THIS HOSE ON OR NEAR 5 CHECK ENTIRE HOSE FOR CUTS CRACKS LEAKS ABRASIONS BULGES OR DAMAGE TO ELECTRICAL LINES MAY RESULT IN DEATH OR SERIOUS INJURY COUPLINGS IF ANY OF THESE CONDITIONS EXIST REPLACE THE HOSE IMMEDIATELY NEVER USE TAPE OR ANY DEVICE TO ATTEMPT TO MEND THE HOSE FOR PROPER AND SAFE OPERATION MAKE SURE THAT YOU HAVE BEEN PROPERLY DECIES EET PROCEDURES REQUIRED FOR WORK ON OR AROUND 6 AFTER EACH USE STORE IN A CLEAN DRY AREA DO NOT EXCEED HOSE WORKING PRESSURE OR ABUSE HOSE IMPROPER USE OR HANDLING OF HOSE COULD RESULT IN BURST OR OTHER HOSE FAILURE KEEP HOSE AS FAR AWAY AS POSSIBLE FROM BODY AND DO NOT PERMIT DIRECT CONTACT DURING USE CONTACT AT THE BURST CAN CAUSE BODILY INJECTION AND SEVERE PERSONAL INJURY HANDLE AND ROUTE HOSE CAREFULLY TO AVOID KINKING CUTTING OR CONTACT WITH HIGH TEMPERATURE SURFACES DO NOT USE IF KINKED DO NOT USE HOSE TO PULL OR LIFT TOOLS POWER UNITS ETC SEE OTHER SIDE A OVL SIHL
10. USE HOSE DO NOT USE KINKED TORN OR DAMAGED HOSE 3 MAKE SURE HYDRAULIC HOSES ARE PROP ERLY CONNECTED TO THE TOOL BEFORE PRESSURING SYSTEM SYSTEM PRESSURE HOSE MUST ALWAYS BE CONNECTED TO TOOL IN PORT SYSTEM RETURN HOSE MUST ALWAYS BE CONNECTED TO TOOL OUT PORT REVERSING CONNECTIONS MAY CAUSE RE VERSE TOOL OPERATION WHICH CAN RESULT IN SEVERE PERSONAL INJURY 4 DO NOT CONNECT OPEN CENTER TOOLS TO CLOSED CENTER HYDRAULIC SYSTEMS THIS MAY RESULT IN LOSS OF OTHER HYDRAULIC FUNCTIONS POWERED BY THE SAME SYSTEM AND OR SEVERE PERSONAL INJURY 5 BYSTANDERS MAY BE INJURED IN YOUR WORK AREA KEEP BYSTANDERS CLEAR OF YOUR WORK AREA IMPORTANT READ OPERATION MANUAL AND SAFETY INSTRUCTIONS FOR THIS TOOL BEFORE USING IT USE ONLY PARTS AND REPAIR PROCEDURES APPROVED BY STANLEY AND DESCRIBED IN THE OPERATION MANUAL TAG TO BE REMOVED ONLY BY TOOL OPERATOR SAFETY TAG P N 15875 shown smaller then actual size HYDRAULIC HOSE REQUIREMENTS HOSE TYPES Hydraulic hose types authorized for use with Stanley Hydraulic Tools are as follows Certified non conductive Wire braided conductive Fabric braided not certified or labeled non conductive Hose listed above is the only hose authorized for use near electrical conductors Hoses listed above are conductive and must never be used near electrical conductors HOSE SAFETY TAGS To help ensure your safety the following DANGER tags are a
11. before each use daily TOOL STICKERS amp TAGS Model Number GD50 ROD DRIVER FLOW 26 34 LPM 7 9 GPM PRESS 105 140 BAR 1500 2000 PSI ACCUMULATOR CHG 42 BAR 600 PSI NITROGEN The safety tag p n 15875 at right is attached to the tool when shipped from the factory Read and understand the safety instructions listed on this tag before removal We suggest you retain this tag and attach it to the tool when not in use 37425 Name Tag 1 FAILURE TO USE HYDRAULIC HOSE LABELED AND CERTIFIED AS NON CONDUCTIVE WHEN USING HYDRAULIC TOOLS ON OR NEAR ELECTRICAL LINES MAY RESULT IN DEATH OR SERIOUS INJURY BEFORE USING HOSE LABELED AND CERTI FIED AS NON CONDUCTIVE ON OR NEAR ELECTRIC LINES BE SURE THE HOSE IS MAINTAINED AS NON CONDUCTIVE THE HOSE SHOULD BE REGULARLY TESTED FOR ELECTRIC CURRENT LEAKAGE IN ACCOR DANCE WITH YOUR SAFETY DEPARTMENT INSTRUCTIONS AHYDRAULIC LEAK OR BURST MAY CAUSE OIL INJECTION INTO THE BODY OR CAUSE OTHER SEVERE PERSONAL INJURY A DO NOT EXCEED SPECIFIED FLOW AND PRESSURE FOR IMPORTANT READ OPERATION MANUAL AND SAFETY INSTRUCTIONS FOR THIS TOOL BEFORE USING IT USE ONLY PARTS AND REPAIR PROCEDURES APPROVED BY STANLEY AND DESCRIBED IN THE OPERATION MANUAL TAG TO BE REMOVED ONLY BY TOOL OPERATOR 3810 SE Naef Road Milwaukie Oregon 97267 USA stanley Hydraulic Tools Division of The Stanley Works D DO NOT LIFT OR CARRY TOOL BY THE HOSES DO NOT AB
12. e warranted subject to the exceptions herein to be free of defects in material and or workmanship at the time of delivery and for a period of 6 months after the date of first usage Seals and diaphragms are warranted to be free of defects in material and or workmanship at the time of delivery and for a period of 6 months after the date of first usage or 2 years after the date of delivery whichever period expires first Warranty for new parts 15 limited to replacement of defective parts only Labor is not covered FREIGHT COSTS Freight costs to return parts to Stanley if requested by Stanley for the purpose of evaluating a warranty claim for warranty credit are covered under this policy if the claimed part or parts are approved for warranty credit Freight costs for any part or parts which are not approved for warranty credit will be the responsibility of the individual SEALS amp DIAPHRAGMS Seals and diaphragms installed in new tools are warranted to be free of defects in material and or workmanship for a period of 6 months after the date of first usage or for a period of 2 years from the shipping date from Stanley whichever period expires first CUTTING ACCESSORIES Cutting accessories such as breaker tool bits are warranted to be free of defects in material and or workmanship at the time of delivery only ITEMS PRODUCED BY OTHER MANUFACTURERS Components which are not manufactured by Stanley and are warranted by their respective manufacturers a
13. ecommended by Stanley Hydraulic Tools Supply hoses must have a minimum working pressure rating of 2500 psi 172 bar Do not exceed the rated flow see Specifications in this manual for correct flow rate and model number Rapid failure of the internal seals may result Always keep critical tool markings such as warning stickers and tags legible Tool repair should be performed by experienced personnel only Make certain that the recommended relief valves are installed in the pressure side of the system Do not use the tool for applications for which it was not intended TROUBLESHOOTING If symptoms of poor performance develop the following chart can be used as a guide to correct the problem When diagnosing faults in operation of the spike driver always check that the hydraulic power source is supplying the cor rect hydraulic flow and pressure to the spike driver as listed in the table Use a flowmeter known to be accurate Check the flow with the hydraulic oil temperature at least 80 F 27 C PROBLEM CAUSE SOLUTION Rod driver does not run Power unit not functioning Check power unit for proper flow and pressure 7 9 gpm 26 34 lpm at 2000 psi 140 bar Couplers or hoses blocked Remove restriction Pressure and return line hoses re Be sure hoses are connected to their versed at ports proper ports Mechanical failure of piston or auto Have inspected and repaired by an matic valve authorized dealer Rod driver does not
14. heck that the hydraulic power source develops a flow of 7 9 gpm 26 34 lpm for HTMA type ll tools EHTMA category D at 2000 psi 105 140 bar 2 Make certain the hydraulic power source is equipped with a relief valve set to open at 2100 2250 psi 145 155 bar minimum 3 Check that the hydraulic circuit matches the tool for open center OC operation CHECK TOOL 1 Make sure the tool contains the correct anvil for the rod size to be driven Use the 5 8 inch anvil Standard in the model GD50132RF Rod Driver for 5 8 inch diameter rod Use the 1 inch anvil standard in the model GD50133RF Rod Driver for 3 4 inch to 1 inch diameter rod Failure to use the correct anvil with the appropriate rod size can result in damage to the tool or personal injury 2 There should be no signs of leaks 3 The tool should be clean with all fittings and fasteners tight CHECK TRIGGER MECHANISM 1 Check that the trigger operates smoothly and is free to travel between the ON and OFF positions CONNECT HOSES 1 Wipe all hose couplers with a clean lint free cloth before making connections 2 Connect the hoses from the hydraulic power source to the hose couplers on the rod driver It is a good practice to connect the return hose first and disconnect it last to mini mize or avoid trapped pressure within the rod driver 3 Observe flow indicators stamped on hose couplers to be sure that oil will flow in the proper direction The female coupler
15. hit effectively Power unit not functioning Check power unit for proper flow and pressure 7 9 gpm 26 34 lpm at 2000 psi 140 bar Couplers or hoses blocked Remove restriction Low accumulator charge pressure Have recharged by an authorized hose will pulse more than normal dealer Fluid too hot above 140 F 60 C Provide cooler to maintain proper fluid temperature Rod anvil is not sliding freely in the Remove clean and replace as neces anvil guide sary Low oil flow from power unit Check power source for proper flow Rod driver operates slow High back pressure Check hydraulic system for excessive back pressure and correct as required 13 SPECIFICATIONS Capacity Rod Anvil 1 2 to 5 8 inch 12 to 16 mm diameter rod model GD50132RF 3 4 to 1 inch 19 to 25 mm diameter rod model GD50133RF FS SIE qm 1500 2000 psi 105 140 bar Maximum BACK Pressure NN ue m 250 psi 17 bar FOTO RN E TC 7 9 gpm 26 34 COUPLES MT TTC V9 HTMA EHTMA Flush Face Type Male amp Female gio m iiu Yes Qu E XKKG Weight cccccccccssssesecsssssssecsussecsuesecsussecsecsessessessessecsessessessessessessessessessessesssssessestssssteaestesesstessessesseeseeses 57 3 lbs 26 kg VALENS ms 25 5 inches 64 8 VE arene ee mama 10 inches 25 4 cm Maximum Fluid Temperaturo SV JET 140 F 60 SPECIAL TOO
16. ic fluid REPAIRS OR ALTERATIONS Any failure or performance deficiency attributable to repairs by anyone which in Stanley s sole judgement caused or contributed to the failure or deficiency MIS APPLICATION Any failure or performance deficiency attributable to mis application Mis application is defined as usage of products for which they were not originally intended or usage of products in such a matter which exposes them to abuse or accident without first obtaining the written consent of Stanley PERMISSION TO APPLY ANY PRODUCT FOR WHICH IT WAS NOT ORIGINALLY INTENDED CAN ONLY BE OBTAINED FROM STANLEY ENGINEERING WARRANTY REGISTRATION STANLEY ASSUMES NO LIABILITY FOR WARRANTY CLAIMS SUBMITTED FOR WHICH NO TOOL REGISTRATION IS ON RECORD In the event a warranty claim is submitted and no tool registration is on record no warranty credit will be issued without first receiving documentation which proves the sale of the tool or the tools first date of usage The term DOCUMENTATION as used in this paragraph is defined as a bill of sale or letter of intent from the first retail customer A WARRANTY REGISTRATION FORM THAT IS NOT ALSO ON RECORD WITH STANLEY WILL NOT BE ACCEPTED AS DOCUMENTATION NO ADDITIONAL WARRANTIES OR REPRESENTATIONS This limited warranty and the obligation of Stanley thereunder is in lieu of all other warranties expressed or implied including merchantability or fitness for a particular purpose except for that provided here
17. in There is no other warranty This warranty gives the purchaser specific legal rights and other rights may be available which might vary depending upon applicable law 17 Stanley Hydraulic Tools 3810 SE Naef Road Milwaukie Oregon 503 659 5660 Fax 503 652 1780 www stanley hydraulic tools com
18. ing the normally recommended fluids fluid temperature should be at or above 50 F 10 C 400 ssu 82 centistokes before use CHARGING THE ACCUMULATOR To check or charge the accumulator the following equip Note ment is required It may be necessary to set the regulator at 650 700 psi 41 48 bar to overcome any pressure drop through Charge kit Part Number 31254 Includes the following the charging system Accumulator tester Part Number 02835 6 Open the valve on the charging assembly hose When the tester gauge reads 600 700 psi41 48 bar close the Charge assembly Part Number 15304 Includes a valve on the charging assembly hose and remove the liquid filled gauge with snub valve hose and fittings charging assembly NITROGEN bottle with a 800 psi 56 bar minimum charge 7 Turn the gauge end of the tester fully counterclockwise not a part of 31254 kit to retract the plunger in the chuck Remove the tester from the charge valve 1 Holding the chuck end of the Stanley tester p n 02835 turn the gauge fully counterclockwise to ensure the stem 8 Replace the valve cap inside the chuck is completely retracted TESTING THE ACCUMULATOR 2 Thread the tester onto the charging valve of the tool ac cumulator do not advance the gauge end into the chuck PRESSURE end Turn as a unit Seat the chuck on the accumulator charging valve by hand tightening only 1 Follow instructions 1 through 3 under CHARGING THE ACCUMULATOR
19. is the inlet coupler Note The pressure increase in uncoupled hoses left in the sun may result in making them difficult to connect When possible connect the free ends of operating hoses together OPERATING PROCEDURES 1 Observe all safety precautions 2 Move the hydraulic circuit control valve to the ON posi tion 3 Place the anvil of the rod driver over the rod to be driven 4 Ensure adequate down pressure is applied to the rod driver before starting the rod driver To start the rod driver press the button on the control valve to the ON position Adequate down pressure is very important When you wish to stop the tool press the button on the control valve to the OFF position INLINE CONTROL VALVE OPERATION The 38632 Inline Control Valve is designed to provide the ON OFF func tions for a hydraulic tool connected to either an OPEN CENTER O C hydraulic system or an CLOSED CENTER C C hydraulic system The valve is to be used with tools which do not have an ON OFF trigger con trol The 38632 Control Valve can be used on hydraulic systems producing up to 10 gpm 38 Ipm with a maximum relief valve setting of 2500 psi 172 bar The valve ports are 8 SAE 3 4 16 thread o ring ports SETTING FOR OPEN CENTER O C OR CLOSED CENTER C C Set the valve to O C or C C before connecting it to the hydraulic system To set the valve for open center operation use a straight blade screw driver to turn the selector sc
20. jury This signal word indicates a potentially hazardous situation which if not avoided may result in property damage This signal word indicates a situation which if not avoided will result in damage to the equipment This signal word indicates a situation which if not avoided may result in damage to the equipment Always observe safety symbols They are included for your safety and for the protection of the tool LOCAL SAFETY REGULATIONS Enter any local safety regulations here Keep these instructions in an area accessible to the operator and mainte nance personnel SAFETY PRECAUTIONS Tool operators and maintenance personnel must always comply with the safety precautions given in this manual and on the stickers and tags attached to the tool and hose To avoid serious injury or death 2 Y JH These safety precautions are given for your safety Review them carefully before 7 operating the tool and before performing general maintenance or repairs Supervising personnel should develop additional precautions relating to the specific work area and local safety regulations If so place the added precautions in the space provided in this manual The GD50 Hydraulic Rod Driver will provide safe and dependable service if oper ated in accordance with the instructions given in this manual Read and understand this manual and any stickers and tags attached to the tool and hoses before opera tion Failure to do so could res
21. rew counter clockwise until it stops To set the valve for closed center operation turn the selector screw clockwise until it stops Be sure you know if you have an OPEN CENTER O C OR CLOSED CENTER C C hydraulic system DO NOT attempt to install or operate the 38632 Valve until you do Incorrect installation or operation of the valve can result in seal failures in the tool cause excessive heat in the hydraulic system and may damage the tool and hydraulic system Understand which type of hydraulic system you are using before installing or operating this valve OPERATION INSTALLING THE VALVE Connect the valve to the hydraulic system as shown in the illustration OPERATING THE VALVE Connect the valve to the tool using the illustration below as a guide Make sure the valve spool on the valve is pushed OFF before connecting the valve to the hydraulic system Make sure the hydraulic system is OFF before connecting the valve to the hydraulic system Connect the valve to the hydraulic system Turn ON the hydraulic system Place the tool to be operated in its operating position Push the valve spool ON to begin operating the tool Push the valve spool OFF to stop operating the tool Turn the hydraulic system OFF before disconnecting the valve Selector Screw IN PRESSURE RETURN COLD WEATHER OPERATION If the rod driver is to be used during cold weather preheat the hydraulic fluid at low engine speed When us
22. ttached to all hose purchased from Stanley Hydrau lic Tools DO NOT REMOVE THESE TAGS If the information on a tag is illegible because of wear or damage replace the tag immediately A new tag may be obtained from your Stanley Distributor THE TAG SHOWN BELOW IS ATTACHED TO CERTIFIED NON CONDUCTIVE HOSE DANGER DANGER 1 FAILURE TO USE HYDRAULIC HOSE LABELED AND CERTIFIED AS NON CONDUCTIVE DO NOT EXCEED HOSE WORKING PRESSURE OR ABUSE HOSE IMPROPER USE OR WHEN USING HYDRAULIC TOOLS ON OR NEAR ELECTRIC LINES MAYRESULT IN DEATH HANDLING OF HOSE COULD RESULT IN BURST OR OTHER HOSE FAILURE KEEP OR SERIOUS INJURY HOSE AS FAR AWAY AS POSSIBLE FROM BODY AND DO NOT PERMIT DIRECT CONTACT FOR PROPER AND SAFE OPERATION MAKE SURE THAT YOU HAVE BEEN PROPERLY DURING USE CONTACT AT THE BURST CAN CAUSE BODILY INJECTION AND SEVERE TRAINED IN CORRECT PROCEDURES REQUIRED FOR WORK ON OR AROUND PERSONAL INJURY ELECTRIC LINES HANDLE AND ROUTE HOSE CAREFULLY TO AVOID KINKING ABRASION CUTTING OR CONTACT WITH HIGH TEMPERATURE SURFACES DO NOT USE IF KINKED DO NOT USE 2 BEFORE USING HYDRAULIC HOSE LABELED AND CERTIFIED AS NON CONDUCTIVE ON HOSE TO PULL OR LIFT TOOLS POWER UNITS ETC OR NEAR ELECTRIC LINES WIPE THE ENTIRE LENGTH OF THE HOSE AND FITTING A RT REMOVE DIR TAND MOSISTURE AND TEST 5 CHECK ENTIRE HOSE FOR CUTS CRACKS LEAKS ABRASIONS BULGES OR DAMAGE TO HOSE FOR MAXIMUM ALLOWABLE CURRENT LEAKAGE INACCORDANCE WITA SAFE TY CO
23. ult in personal injury or equipment damage Operator must start in a work area without bystanders The operator must be familiar with all prohib ited work areas such as excessive slopes and dangerous terrain conditions Establish a training program for all operators to ensure safe operation Do not operate the tool unless thoroughly trained or under the supervision of an instructor Always wear safety equipment such as goggles ear and head protection and safety shoes at all times when operating the tool Do not inspect or clean the tool while the hydraulic power source is connected Accidental engage ment of the tool can cause serious injury Always connect hoses to the tool hose couplers before energizing the hydraulic power source Be sure all hose connections are tight Do not operate the tool at oil temperatures above 140 F 60 C Operation at higher temperatures can cause higher than normal temperatures at the tool which can result in operator discomfort Do not operate a damaged improperly adjusted or incompletely assembled rod driver Do not weld cut with an acetylene torch or hardface the rod driver anvil or guide housing To avoid personal injury or equipment damage all tool repair maintenance and service must only be performed by authorized and properly trained personnel Always replace parts with replacement parts recommended by Stanley Hydraulic Tools Check fastener tightness often and
24. ydraulic tools other than routine maintenance must be performed by an authorized and certified dealer Please read the fol lowing warning SERIOUS INJURY OR DEATH COULD RESULT FROM THE IM PROPER REPAIR OR SERVICE OF THIS TOOL REPAIRS AND OR SERVICE TO THIS TOOL MUST ONLY BE DONE BY AN AUTHORIZED AND CERTIFIED DEALER For the nearest authorized and certified dealer call Stanley Hydraulic Tools at the number listed on the back of this manual and ask for a Customer Service Representative 9 SAFETY SYMBOLS Safety symbols and signal words as shown below are used to emphasize all operator maintenance and repair actions which if not strictly followed could result in a life threatening situation bodily injury or damage to equip ment NOTICE IMPORTANT DANGER WARNING CAUTION CAUTION NOTICE IMPORTANT This is the safety alert symbol It is used to alert you to potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death This safety alert and signal word indicate an imminently hazardous situa tion which if not avoided will result in death or serious injury This safety alert and signal word indicate a potentially hazardous situation which if not avoided could result in death or serious injury This safety alert and signal word indicate a potentially hazardous situation which if not avoided may result in minor or moderate in
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